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Building a Modular Home

Bob meets with Pat Fricchione from Simplex Industries of Scranton, Penn. to discuss the modular home industry and specifically the home being built in western Massachusetts� Berkshire Hills. Simplex delivers homes all over the Northeast and Mid-Atlantic states. Today�s modular homes are designed to meet the needs of the modern discriminating homebuyer. The materials used in a modular home are essentially the same as those used in a site built one. They can be customized or built from existing floor plans. The homeowner gets the advantage of buying in bulk for all the materials in the home. And its always perfect weather in the factory, so there are no delays due to rain or snow. A typical home can be built in a week at the factory and delivered to the home site in ready-to-assemble pieces.
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Building a Modular Home

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" Tell us a little bit about simplex industries how old a company as well we started in 1971. Originally how we originally started was the fact that my grandfather immigrated here. From Italy in the twenties yeah and then he was in plumbing and heating business and one the first things the patent was say. Coal stoker called. A simplex coal stoker and this is was it was an automatic what's a coal -- Well it's call stuck in this area was a rich and underside -- I can't even got a town called anthracite that's right and what was it was an automatic worm feed meeting they use that the coal vent. And he used to automatic feed the coal into the into the fire pot. And I used to heat up the houses and what happened and so that company evolved into Steve Monica what it will probably what what happened was who have you know without the coal industry act going down. They needed to -- do something else and are always interesting construction so one day they're just in around the kitchen table and they talked about. Hey let's get into this out modular home industry and that's how and I'll start now. Pat what is the the basic difference between a stick built house and a modular house. Well there really isn't any difference on the fact that you know we're still using the same materials as -- that's stick built recycled on. I think that we're doing is we're filling -- You're still receiving flatbed trucks with. Two by fours and two by twelve halves if cavity yeah right differences when you -- an -- you're just getting a small truckload of lumber here -- of falsifying. Carlos truckloads and that's other material and -- and obviously we have more men here -- you know building -- control requirements we have different stations different departments. And what they do is they build they work as teams and they build a house basically it is cellular life. And as the house comes further down a similar line or markets whether it's. And of course the big advantages as you have to deal with the weather you've got right -- certain types because they'll fall months you know out of the year whether it's snow sleet rain. So a house like this Wendy Westport model could theoretically be built in a weakening and inside the plant here that's correct and it's a lovely house how big is that there. This is approximately -- 2500 square feet its say up workbox act Cape Cod style home so there are four modules that get put together correct. And as you say we have the airport China which gives a lot of curb appeal -- farmer's porch."

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Tour of the Simplex Modular Home Factory
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In this segment, Bob continues his tour of the Simplex Industries manufacturing facility. The plant workers are precutting all the plywood for the project house, as well as other homes currently in production. The efficiencies created by using large industrial saws to make precision cuts save the homeowner time and money and insures a well-fit house. Dave Boniello from Simplex guides Bob through the cutting area of the plant. Unlike most site-built homes, all of the scraps of wood are sent back to the manufacturers for recycling. Continuing the tour, Boniello and Bob overlook the construction of the interior and exterior walls, which are built in sheets of varying heights (up to 10 feet) and up to 64 feet long. Modular homes are built from the inside out, meaning that instead of starting with the exterior framing, roof and sheathing, the modular home starts with interior walls and drywall. The wallboard is glued and screwed to the stud walls, which have additional steel plates to maintain rigidity during transport. Bob points out the inspection process for a modular home is different than for a site built home as local inspectors would be hard pressed to visit the Simplex plant in Pennsylvania. Simplex hires independent inspectors that are certified in multiple states and they correspond with local building inspectors to insure that all building codes are met or exceeded.

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Bob Vila oversees the delivery and installation of the first section of the second floor of the home. Bob points out the complexity of this piece with its dormers and gable roof. The modern modular home can be conformed to the homeowner�s desires. The second floor in this example has an exterior egress, which will eventual permit the owner to walk out onto a small terrace over the first floor dining room. In Simplex modular homes, the ceilings of the first floor are manufactured separately from the floors of the second story. This separation of shared framing timbers reduces the noise transfer from one floor to the next. This is especially advantageous in multi-family dwellings and business structures.

Modular Home Construction Basics
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In this segment, Bob Vila visits the Simplex Industries modular home plant in Scranton, Pennsylvania, where the Home Again project house is being constructed. Dave Boniello, the Vice President of Marketing for Simplex, gives Bob a plant tour during the construction of the Modular Mountain Retreat project house. Building the majority of a home in a factory and delivering it to the home site to be assembled presents unique challenges. Simplex Industries, a privately owned company that ships over 400 homes a year, utilizes a mix of traditional framing techniques and modular home construction-specific practices to ensure that the transportation of the home from factory to building site can be accomplished without structural or cosmetic damage to the house. Examples include eaves that can be folded up for transportation, extra bracing between walls and floors, metal shielding to protect rough electrical work, and drywall that is glued, not screwed, into place.

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Bob Vila takes an early interior tour of the modular home. Bob is in a 15-foot-wide-by-48-foot long section. The flooring and walls are almost complete and much of the molding and cabinetry is laid out and ready to be installed. Bob points out an archway between the kitchen and breakfast nook�one of the pleasant design surprises that can be added to a custom modular home. The floors are Bellawood�s Northern Red Oak with a gunstock finish. The darker finish gives a more sophisticated and formal look to the room. The hardwood floors are installed in the modular home just as they wood be in a site built home. Mike Snyder from Mike�s Flooring, a flooring sub contractor in the Simplex plant, points out the quality of the Bellawood noting it has very few flaws and a durable finish. The flooring is left incomplete where two pieces of the modular home are to be attached. On site, quick work will be made of the few details left when the large modular sections are joined.

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